CAGE 1523852 - Caterpillar

Remove the electrical power from the ECM.
Disconnect the connectors at the valve cover base at the valve cover base.
Restore the electrical power to the ECM.
Fabricate a jumper wire that will be long enough to short circuit two terminal locations at the connector that is at the valve cover base. Crimp connector pins on both ends of the jumper wire.
Illustration 6 g01161304
Terminal locations for the connector at the valve cover base
(Terminal 1) Injector 1 return
(Terminal 2) Injector 2 return
(Terminal 3) Injector 3 return
(Terminal 4) Injector 4 return
(Terminal 5) Injector 5 return
(Terminal 6) Injector 6 return
(Terminal 7) Injector 1 & 2 supply
(Terminal 8) Injector 3 & 4 supply
(Terminal 9) Injector 5 & 6 supply
At the connector at the valve cover base, insert one end of the jumper wire into the connector socket for the suspect injector's supply wire. Insert the other end of the jumper wire into the connector socket for the suspect injector's return wire. This will replace the injector solenoid with a short circuit.
Perform the "Injector Solenoid Test" at least two times.
Repeat this test for each suspect circuit. Stop the "Injector Solenoid Test" before handling the jumper wire. Restore the wiring to the original configuration. Expected Result:Cat ET displays "Short" for each of the circuits that were jumpered.Results:
OK - Cat ET displays "Short" for each circuit that was jumpered. The harness between the ECM and the connector at the valve cover base does not have an open circuit. Proceed to Test Step 6.
Not OK - Cat ET displays "Open" for the cylinder with the jumper wire. There is a problem in the wiring between the ECM and the connector at the valve cover base. Proceed to Test Step 7.Test Step 6. Check the Harness between the ECM and the Valve Cover Base for a Short Circuit
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Remove the electrical power from the ECM.
Disconnect the connectors at the valve cover base.
Restore the electrical power to the ECM.
Perform the "Injector Solenoid Test" at least two times. Expected Result:All of the cylinders indicate "Open" on Cat ET.Results:
OK - All cylinders indicate "Open" on Cat ET. The ECM and the engine harness are OK. Proceed to Test Step 7.
Not OK - One or more cylinders indicate "Short" on Cat ET. Note the cylinders that indicate "Short". Proceed to Test Step 8.Test Step 7. Check the Injector Harness Under the Valve Cover for an Open Circuit or a Short Circuit
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Remove the electrical power from the ECM.
Remove the valve cover in order to gain access to the suspect injector.
Disconnect the harness connector from the suspect injector.
Illustration 7 g01147088
Connector terminals for the injector solenoid
Thoroughly clean the terminals on the injector solenoid and on the harness connector.
Use a jumper wire to short circuit the connector terminals for the suspect injector. This will effectively replace the injector solenoid with a short circuit.
Restore the electrical power to the ECM.
Perform the "Injector Solenoid Test" at least two times. Note: The injector solenoid